Komatsu PC130-8 Hydraulic Excavator Shop Manual SEN03763-15 PDF

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Komatsu PC130-8 Hydraulic Excavator Shop Manual SEN03763-15 – PDF DOWNLOAD

FILE DETAILS:

Komatsu PC130-8 Hydraulic Excavator Shop Manual SEN03763-15 – PDF DOWNLOAD 

Language : English
Pages : 1064
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu PC130-8 Hydraulic Excavator Shop Manual SEN03763-15 – PDF DOWNLOAD 

SERIAL NUMBERS 80001 and up

How to read the shop manual 
1. Composition of shop manual
This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard
This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-section explains the structure and function of each component. It
serves not only to give an understanding of the structure, but also serves as reference material for
troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly
and service.
20. Standard value table
This section explains the standard values for new machine and judgement criteria for testing,
adjusting, and troubleshooting. This standard value table is used to check the standard values in
testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly
This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.

TABLE OF CONTENTS:

Komatsu PC130-8 Hydraulic Excavator Shop Manual SEN03763-15 – PDF DOWNLOAD 

SERIAL NUMBERS 80001 and up

Cover 1
00 Index and foreword 3
Index 3
Composition of shop manual 4
Table of contents 6
Foreword and general information 15
Safety notice 16
How to read the shop manual 21
Explanation of terms for maintenance standard 23
Handling of electric equipment and hydraulic component 25
Handling of connectors newly used for engines 34
How to read electric wire code 37
Precautions when carrying out operation 40
Method of disassembling and connecting push-pull type coupler 43
Standard tightening torque table 46
Conversion table 50
01 Specification 57
Specification and technical data 57
Specification dimension drawings 58
Working range diagram 59
Specifications 60
List of weights 64
List of lubricant and coolant to be filled 66
10 Structure, function and maintenance standard 69
Engine and cooling system 69
Engine mount 70
PTO 71
Cooling system 72
Power train 75
Power train 76
Swing circle 77
Swing machinery 78
Undercarriage and frame 81
Track frame 82
Idler cushion 83
Idler 84
Track roller 85
Carrier roller 86
Sprocket 87
Track shoe 88
Hydraulic system, Part 1 93
Hydraulic equipment layout drawing 94
Valve control 96
Hydraulic tank and filter 98
Hydraulic pump 100
Hydraulic system, Part 2 129
Control valve 130
CLSS 140
Functions and operation by valve 144
Hydraulic system, Part 3 175
PPC valve 176
Swing motor 191
Travel motor 199
Center swivel joint 208
Solenoid valve 210
Accumulator 214
Anti-drop valve for boom 216
Anti-drop valve for arm 221
Hydraulic cylinder 226
Work equipment 229
Work equipment 230
Dimensions of components 232
Cab and its attachments 237
Air conditioner 238
Electrical system 241
Electronic control system 242
Machine monitor system 274
KOMTRAX system 288
Sensor 290
20 Standard value table 299
Standard service value table 299
Standard value table for engine related parts 300
Standard value table for chassis related parts 301
30 Testing and adjusting 311
Testing and adjusting, Part 1 311
Precautions before work 313
Tools for testing, adjusting, and troubleshooting 314
Sketches of special tools 319
Testing engine speed 320
Testing exhaust temperature 321
Checking exhaust gas color 322
Adjusting valve clearance 323
Testing compression pressure 325
Testing blow-by pressure 327
Testing engine oil pressure 328
Reduced cylinder mode operation 329
No-injection cranking 329
Handling fuel system parts 330
Releasing residual pressure from fuel system 330
Testing fuel pressure 331
Testing fuel return rate and fuel leakage 332
Bleeding air from fuel circuit 334
Checking fuel circuit for leakage 335
Testing and adjusting alternator belt tension 336
Checking and adjusting air conditioner compressor belt tension 337
Testing swing circle bearing clearance 338
Checking and adjusting track shoe tension 339
Testing and adjusting oil pressure in work equipment, swing, and travel circuits 341
Testing control circuit basic pressure 344
Testing and adjusting oil pressure in pump PC control circuit 345
Testing and adjusting oil pressure in pump LS control circuit 348
Testing solenoid valve output pressure 351
Testing PPC valve output pressure 355
Adjusting play of work equipment and swing PPC valves 356
Checking parts which cause hydraulic drift of work equipment 357
Testing and adjusting travel deviation 359
Releasing residual pressure from hydraulic circuit 361
Testing oil leakage 364
Bleeding air from each part 367
Checking cab tipping stopper 369
Installation and adjustment of mirrors and camera 370
Inspection of air conditioner Recirc/Fresh air filter 381
Testing and adjusting, Part 2 383
Special functions of machine monitor 384
Testing and adjusting, Part 3 435
Handling voltage circuit of engine controller 436
Preparation work for troubleshooting of electrical system 437
Procedure for testing diodes 442
Pm Clinic service 443
40 Troubleshooting 449
Failure code table and fuse locations 449
Precautions before work 450
Failure code table 451
Fuse locations 455
General information on troubleshooting 459
Points to remember when troubleshooting 460
Sequence of events in troubleshooting 461
Checks before troubleshooting 462
Classification and procedures for troubleshooting 463
Information in troubleshooting table 464
Phenomena looking like troubles and troubleshooting Nos 466
Connection table for connector pin numbers 469
T- branch box and T- branch adapter table 505
Troubleshooting by failure code, Part 1 509
Failure code [989L00] Engine controller lock caution 1 511
Failure code [989M00] Engine controller lock caution 2 511
Failure code [989N00] Engine controller lock caution 3 512
Failure code [AA10NX] Air cleaner clogging 513
Failure code [AB00KE] Charge voltage low 514
Failure code [B@BAZG] Eng oil press low 516
Failure code [B@BAZK] Eng oil level low 517
Failure code [B@BCNS] Eng coolant overheat 518
Failure code [B@BCZK] Eng water level low 520
Failure code [B@HANS] Hydr oil overheat 522
Failure code [CA111] ECM critical internal failure 524
Failure code [CA115] Eng Ne and Bkup speed sensor error 527
Failure code [CA122] Charge air press sensor high error 528
Failure code [CA123] Charge air press sensor low error 530
Failure code [CA131] Throttle sensor high error 532
Failure code [CA132] Throttle sensor low error 534
Failure code [CA144] Coolant temp sensor high error 536
Failure code [CA145] Coolant temp sensor low error 538
Failure code [CA153] Charge air temp sensor high error 540
Failure code [CA154] Charge air temp sensor low error 542
Failure code [CA155] Chg air temp high speed derate 542
Failure code [CA187] Sensor sup 2 volt low error 543
Failure code [CA221] Ambient air press sensor high error 544
Failure code [CA222] Ambient air press sensor low error 546
Failure code [CA227] Sensor sup 2 volt high error 547
Failure code [CA234] Eng overspeed 548
Failure code [CA238] Ne speed sensor sup volt error 550
Failure code [CA271] IMV/PCV1 short error 552
Failure code [CA272] IMV/PCV1 open error 553
Failure code [CA322] Injector #1 (L #1) system open/short error 554
Failure code [CA324] Injector #3 (L #3) system open/short error 556
Failure code [CA331] Injector #2 (L #2) system open/short error 558
Failure code [CA332] Injector #4 (L #4) system open/short error 560
Troubleshooting by failure code, Part 2 563
Failure code [CA342] Calibration code incompatibility 565
Failure code [CA351] Inj drive circuit error 566
Failure code [CA352] Sensor sup 1 volt low error 569
Failure code [CA386] Sensor sup 1 volt high error 570
Failure code [CA435] Abnormality in engine oil pressure switch 572
Failure code [CA441] Battery voltage low error 573
Failure code [CA442] Battery voltage high error 574
Failure code [CA449] Rail press very high error 575
Failure code [CA451] Rail press sensor high error 576
Failure code [CA452] Rail press sensor low error 578
Failure code [CA488] Chg air temp high torque derate 579
Failure code [CA553] Rail press high error 580
Failure code [CA559] Rail press low error 581
Failure code [CA689] Eng Ne speed sensor error 584
Failure code [CA731] Eng Bkup speed sensor phase error 586
Failure code [CA757] All persistent data lost error 587
Failure code [CA778] Eng Bkup speed sensor error 588
Failure code [CA1633] KOMNET datalink timeout error 590
Failure code [CA2185] Throttle sens sup volt high error 592
Failure code [CA2186] Throttle sens sup volt low error 594
Failure code [CA2249] Rail press very low error 594
Failure code [CA2311] Abnormality in IMV solenoid 595
Failure code [D110KB] Battery relay drive short 596
Failure code [D19JKZ] Personal code relay abnormality 598
Failure code [D862KA] GPS antenna discon 600
Failure code [DA22KK] Pump solenoid power low error 602
Failure code [DA25KP] 5V sensor 1 power abnormality 604
Failure code [DA26KP] 5V sensor 2 power abnormality 607
Failure code [DA29KQ] Model selection abnormality 608
Troubleshooting by failure code, Part 3 611
Failure code [DA2RMC] CAN discon (Pump controller detected) 614
Failure code [DAF8KB] Short circuit in camera power supply 616
Failure code [DAFGMC] GPS module error 618
Failure code [DAFRMC] CAN discon (Monitor detected) 620
Failure code [DGH2KB] Hydr oil sensor short 622
Failure code [DHPAMA] Pump press sensor abnormality 624
Failure code [DHSFMA] Travel left forward PPC press sensor abnormality 626
Failure code [DHSGMA] Travel right forward PPC press sensor abnormality 628
Failure code [DHSHMA] Travel left reverse PPC press sensor abnormality 630
Failure code [DHSJMA] Travel right reverse PPC press sensor abnormality 632
Failure code [DHX1MA] Overload sensor abnormality (Analog) 634
Failure code [DV20KB] Travel alarm short circuit 635
Failure code [DW43KA] Travel speed sol discon 636
Failure code [DW43KB] Travel speed sol short 637
Failure code [DW45KA] Swing brake sol discon 638
Failure code [DW45KB] Swing brake sol short 640
Failure code [DW91KA] Travel junction sol discon 642
Failure code [DW91KB] Travel junction sol short 644
Failure code [DWJ0KA] Merge-divider sol discon 646
Failure code [DWJ0KB] Merge-divider sol short 648
Failure code [DWK0KA] 2-stage relief sol discon 650
Failure code [DWK0KB] 2-stage relief sol short 652
Troubleshooting by failure code, Part 4 655
Failure code [DXA8KA] PC-EPC sol discon 656
Failure code [DXA8KB] PC-EPC sol short 658
Failure code [DXE4KA] Service current EPC discon 660
Failure code [DXE4KB] Service current EPC short 662
Failure code [DY20KA] Wiper working abnormality 664
Failure code [DY20MA] Wiper parking abnormality 666
Failure code [DY2CKA] Washer drive discon 668
Failure code [DY2CKB] Washer drive short 670
Failure code [DY2DKB] Wiper drive (for) short 672
Failure code [DY2EKB] Wiper drive (rev) short 674
Troubleshooting of electrical system (E-mode) 677
Before carrying out troubleshooting of electrical system 679
Information in troubleshooting table 681
E-1 When starting switch turned ON, machine monitor displays nothing 682
E-2 When starting switch turned ON (before starting engine), basic check item lights up 684
E-3 Engine does not start (Engine does not turn) 687
E-4 Preheater does not operate 690
E-5 Automatic warm-up system does not operate (in cold season) 692
E-6 All work equipment, swing, and travel mechanism do not move or cannot be locked 694
E-7 Precaution lights up while engine is running 696
E-8 Emergency stop item lights up while engine is running 701
E-9 Engine coolant temperature gauge does not indicate normally 702
E-10 Hydraulic oil temperature gauge does not indicate normally 703
E-11 Fuel level gauge does not indicate normally 705
E-12 Contents of display by machine monitor are different from applicable machine 707
E-13 Machine monitor does not display some items 707
E-14 Function switch does not work 707
E-15 Auto-decelerator does not operate normally 708
E-16 Working mode does not change 709
E-17 Travel speed does not change 710
E-18 Alarm buzzer cannot be stopped 711
E-19 Windshield wiper and window washer do not operate 712
E-20 Power maximizing function does not operate normally 716
E-21 Swing holding brake does not operate normally 718
E-22 Travel alarm does not sound or does not stop sounding 720
E-23 Air conditioner does not operate normally (including air conditioner abnormality record) 721
E-24 While starting switch is in OFF position, service meter is not displayed 733
E-25 Machine monitor cannot be set in service mode 733
E-26 Monitoring function does not display lever control signal normally 734
E-27 KOMTRAX system does not operate normally 750
Troubleshooting of hydraulic and mechanical system (H-mode) 753
Information contained in troubleshooting table 755
System chart for hydraulic and mechanical systems 756
H-1 Speed or power of all work equipment, swing, and travel are low 758
H-2 Engine speed sharply drops or engine stalls 759
H-3 No work equipment, travel and swing move 760
H-4 Abnormal noise is heard from around hydraulic pump 760
H-5 Fine control mode does not function 761
H-6 Speed or power of boom is low 762
H-7 Speed or power of arm is low 763
H-8 Speed or power of bucket is low 764
H-9 Work equipment does not move in its single operation 765
H-10 Hydraulic drift of work equipment is large 766
H-11 Time lag of work equipment is large 767
H-12 Power maximizing function does not operate normally 767
H-13 Work equipment loaded more is slower during compound operation 768
H-14 Boom RAISE speed is low in compound operation of swing + boom RAISE 768
H-15 Travel speed lowers largely during compound operation of work equipment/swing + travel 769
H-16 Machine deviates during travel 770
H-17 Travel speed is low 771
H-18 Machine cannot be steered easily or steering power is low 772
H-19 Travel speed does not change or it is kept low or high 773
H-20 Track does not move (Only either side) 773
H-21 Machine does not swing 774
H-22 Swing acceleration or swing speed is low 775
H-23 Excessive overrun when stopping swing 776
H-24 When upper structure stops swinging, it makes large shock 777
H-25 When upper structure stops swinging, it makes large sound 777
H-26 Hydraulic drift of swing is large 778
H-27 Flow rate in attachment circuit cannot be adjusted 779
Troubleshooting of engine (S-mode) 781
Method of using troubleshooting chart 784
S-1 Starting performance is poor 788
S-2 Engine does not start 789
S-3 Engine does not pick up smoothly 792
S-4 Engine stops during operations 793
S-5 Engine does not rotate smoothly 794
S-6 Engine lacks output (or lacks power) 795
S-7 Exhaust smoke is black (incomplete combustion) 796
S-8 Oil consumption is excessive (or exhaust smoke is blue) 797
S-9 Oil becomes contaminated quickly 798
S-10 Fuel consumption is excessive 799
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) 800
S-12 Oil pressure drops 801
S-13 Oil level rises (Entry of coolant or fuel) 802
S-14 Coolant temperature becomes too high (overheating) 803
S-15 Abnormal noise is made 804
S-16 Vibration is excessive 805
50 Disassembly and assembly 807
General information on disassembly and assembly 807
Precautions before work 808
How to read this manual 809
Coating materials list 811
Special tool list 814
Sketch of special tool 818
Engine and cooling system 823
Removal and installation of fuel supply pump assembly 824
Removal and installation of fuel injector assembly 827
Removal and installation of front oil seal 830
Removal and installation of rear oil seal 832
Removal and installation of cylinder head assembly 835
Removal and installation of radiator assembly 845
Removal and installation of aftercooler assembly 847
Removal and installation of work equipment oil cooler assembly 849
Removal and installation of engine and work equipment pump assembly 851
Removal and installation of fuel tank assembly 859
Power train 863
Removal and installation of travel motor and final drive assembly 864
Disassembly and assembly of travel motor and final drive assembly 866
Removal and installation of swing motor and swing machinery assembly 903
Disassembly and assembly of swing machinery assembly 905
Removal and installation of swing circle assembly 911
Undercarriage and frame 913
Disassembly and assembly of track roller 914
Disassembly and assembly of idler assembly 917
Disassembly and assembly of recoil spring 920
Spreading and installation of track shoe assembly 923
Removal and installation of sprocket 925
Removal and installation of revolving frame assembly 926
Removal and installation of counterweight assembly 928
Hydraulic system 931
Removal and installation of center swivel joint assembly 932
Disassembly and assembly of center swivel joint assembly 934
Removal and installation of hydraulic tank assembly 935
Removal and installation of work equipment pump assembly 938
Removal and installation of control valve assembly 942
Disassembly and assembly of control valve assembly 946
Disassembly and assembly of work equipment PPC valve assembly 958
Disassembly and assembly of travel PPC valve assembly 960
Removal and installation of anti- drop valve for boom assembly 963
Removal and installation of anti- drop valve for arm assembly 965
Disassembly and assembly of anti-drop valve assembly 967
Disassembly and assembly of hydraulic cylinder assembly 968
Work equipment 975
Removal and installation of work equipment assembly 976
Cab and its attachments 981
Removal and installation of operator’s cab assembly 982
Removal and installation of operator cab glass (stuck glass) 985
Removal and installation of front window assembly 995
Removal and installation of floor frame assembly 1002
Removal and installation of front wiper assembly 1006
Removal and installation of work equipment control lever assembly 1014
Electrical system 1025
Removal and installation of air compressor assembly 1026
Removal and installation of air conditioner condenser 1027
Removal and installation of air compressor unit assembly 1028
Removal and installation of KOMTRAX communication modem assembly 1031
Removal and installation of monitor assembly 1032
Removal and installation of pump controller assembly 1034
Removal and installation of engine controller assembly 1036
90 Diagrams and drawings 1039
Hydraulic diagrams and drawings 1039
Hydraulic circuit diagram (1/2) 1041
Hydraulic circuit diagram (2/2) 1043
Electrical diagrams and drawings 1047
Electrical circuit diagram (1/6) 1049
Electrical circuit diagram (2/6) 1051
Electrical circuit diagram (3/6) 1053
Electrical circuit diagram (4/6) 1055
Electrical circuit diagram (5/6) 1057
Electrical circuit diagram (6/6) 1059
Connectors table and arrangement drawing 1061

IMAGES PREVIEW OF THE MANUAL:

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